0492b00000 carryall (carryall i and carryall ii gasoline and... · bearing and oil seal remover...
TRANSCRIPT
0492B00000
WARNING
This manual is to be used for identification
and ordering of service parts only. Be sure
to read and use the maintenance and service
manual for any repair.
41 52 Washington Road
P.O. Box 204658
Augusta, Georgia 3091 7-4658 USA
Telephone: 706-863-3000
FAX: 706-860-7231
@ 1992, Club Car Inc. All Rights Reserved
INDEX CONTENTS
MAINTENANCE AND SERVICE TOOLS
BODY AND TRIM SECTION 1 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Front Cowl -- Carryall-l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Front Cowl -- Carryall-I1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Rear Covers -- Carryall-l and Carryall-I1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Seat Bottomandseat Backs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 TiltBedand Latch -- Carryall-l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 TiltBedandPropRod -- Carryall-ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Tilt Bedand Latch -- Carryall-ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
DRIVE UNIT SECTION 2 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
BRAKES. PEDAL AND CABLE ASSEMBLY SECTION 3 Brake Cluster. Right and Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 BrakePedalandCableAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
STEERING AND FRONT SUSPENSION SECTION 4 Steering Column -- Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Steering Column -- Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Front Suspension Assembly -- A-Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Front Suspension Assembly -- Delta A-Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
ELECTRICAL AND BATTERY SECTION 5 Wiring -- Gas Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 ElectricalComponent Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Starter Generator -- Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Starter Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 F&R Shifter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Reverse Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
ENGINE SECTION 6 . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-8
FUEL AND INTAKE SYSTEM SECTION 7 Fuel System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Governor Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Expansionchamber. Chokeand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Governorand Acceleratorcables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
EXHAUST SYSTEM SECTION 8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
TORQUE CONVERTER SECTION 9 Drive Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 DrivenClutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
TRANSMISSION AND GOVERNOR SECTION 10 Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
REAR SUSPENSION -- GAS VEHICLE SECTION 11 RearSuspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner Frame Assembly 11-4
ELECTRICAL -- ELECTRIC VEHICLE SECTION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring -- Electric Vehicle 12-2
V-Glidewiperswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Resistorand Board Assembly-V-Glide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward and Reverse Switch Assembly 12-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring -- Solid State Controller 12-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward and Reverse Switch -- Solid State Controller 12-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Glide Wiper Switch -- Solid State Controller 12-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Buzzer -- Frame Mounted 12-16
ReverseBuzzer-DashMounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
CHARGERS SECTION 13 Model13800Accu-Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Modell4000Ultra-Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
MOTOR SECTION 14 CLUB CARModel#1012191 and#1014678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
REAR SUSPENSION ASSEMBLY -- ELECTRIC VEHICLE SECTION 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension Assembly -- Electric Vehicle 15-2
USING THE ILLUSTRATED PARTS LIST
This Parts List Manual is to be used for identification and ordering of Service Parts for the Carryall-l and Carryall-11 utility vehicles.
The first four (4) sections include information common to both the Carryall Gas and Carryall Electric vehicles. Sections 5 through 11 contain information related solely to the Carryall Gas vehicles while sections 12 through 15 relate solely to the Carryall-l Electric.
The Manual Numerical Index will help provide quick reference to each section.
INDEX GAS b.
INDEX
INDEX
ELECTRIC 3
ELECTRICAL
BATTERY CHARGER
MOTOR
REAR SUSPENSION
MAINTENANCE SERVICE TOOLS DESCRIPTION PART NO . Internal Retaining Pliers ................... ...... ....................................................................................................... 1013593
Brake Adjusting Tool ..................... ....... ........................................................................................................ 1013582
Volt Ohm Meter ....................... ..... ........................................................................................................... 1011480
Continuity Tester ...................... .. .. .............. .................................................................................................... 1011273
Retaining Ring Pliers (45" External) .................................................................................................................... 1012549
Retaining Ring Pliers (90" Internal) ................... ...... .......................................................................................... 1012560
Keyswitch Tool .................... ..................... .................................................................................................... 1012801
Seal Puller ....................... ..... ........................................................................................................................ 1012809
Bearing Puller ......................... .. ..................................................................................................................... 1012811
Bearing Puller Wedge Attachment .......................................................................................................................... 1012812
Tachometer ................... .. ................................................................................................................................ 1016112
Drive Clutch Puller .............................................................................................................................................. 1014496
Clutch Alignment Tool ......................................................................................................................................... 1014498
Touch-Up Paint - Beige ................... ....... ...................................................................................................... 1011981
Touch-Up Paint - White ........................................................................................................................................ 1013145
Transmission Tool Kit ........................................................................................................................................... 1014115
Drive Unit Pinion Seal Tool ................................................................................................................................... 1014161
Drive Unit Axle Seal Tool ...................................................................................................................................... 1014162
Steering Column Bearing Press Tool .................... .... ...................................................................................... 1014264
Steering Column Retaining Ring Tool ....................... ... ...................................................................................... 1014259
Battery Terminal Protector .................................................................................................................................... 1014305
Dry Moly Lubricant .............................................................................................................................................. 1012151
Flexible Cowl Repair Kit .................................................................................................................................. 1014963
Hydrometer ........................................................................................................................................................ 1011478
Battery Tester (Discharge Machine) ..................... ... ..... .............................................................................. 1010687
Battery Thermometer ................... .. .. ... .......................................................................................................... 101 1767
Fly Wheel Puller Kit ............................................................................................................................................. 1016627
Valve Seat Cutter Holder Bar ................................................................................................................................ 1016551
Valve Seat Cutter Holder ..................................................................................................................................... 1016552
Valve Seat Cutter 45" (32mm Diameter) ............................................................................................................. 1016553
Valve Seat Cutter 45" (35mm Diameter) .................... .. ........................................................................................ 1016554
Valve Seat Cutter 32" (35mm Diameter) .................... .. ...................................................................................... 1016555
Clutch Tool Kit .................................................................................................................................................... 1014510
Spring Tune-up Kit (OHV Engine) ................................................................................................................... 1016110-02
................... ........................................................................................................... Compression Gauge ... 1016410-01
............................................................................................................................ Adapter ..................... .. 1016410-02
........................ ............................................................................................. Valve Spring Compressor .... 1016411-01
...................................................................................................................................................... Adapter 1016411-02
........................................................................................................................................ Valve Guide Reamer 1016412-01
Arbor ......................................................................................................................................................... 1016412-02
.................................................................................................................. Valve Clearance Adjuster Screw Holder 1016413
......................................................................................................... .................... Piston Ring Compressor Kit .. 1016414
................................................................................................................................................. Piston Ring Plier 1016415
............................................................................................................................................... Bearing Driver Set 1016416
....................................................................................... .................... Bearing and Oil Seal Remover Assembly .. 1016417
.......................................................................................................................................................... Gear Yoke 1016418
................................................................................................................................. Generator Belt Tension Tool 1016867
................................................................................................. .................. Muffler Spring Tool ................... 1016712
Please refer to the Maintenance and Service Manual for proper tool application .
Section 1
BODY AND TRIM FRONT AND REAR COVERS
1
DETAIL A
TRIM
TRIM ITEM
NUMBER
1 2 3 4 5 5 6 7 8 9
10 10 10 10 10A 10A 10A 10A 10A 11 12
12
13 14 15 15 16 17 18 18 18 18 20 21 22 23 24 25
PART NUMBER
1014883 1012499 1013344 1016630 101660442 1016621-04 1013343 1015032 1010984 1012186 101651441 101651442 101651443 101651445
7271 1015672 1015674 1015673 1015676 1012505 1012415
1012531
1012530 1014645 1015884 1015717 1015437 1014738 1015397 1015396 1015394 1015395 1016094 1015437 1015475 1015476 1016083 1014771
2 3 DESCRIPTION
DASH WARNING DECAL STEERING COLUMN BOOT DASH COMPONENT, LEFT (BLACK) OIL LIGHT CENTER DASH PANEL WITHOUT OIL LIGHT OPENING (BLACK) CENTER DASH PANEL WITH OIL LIGHT OPENING (BLACK) DASH COMPONENT, RIGHT (BLACK) MAT, FLOOR LUG NUT PACKAGE DUST SEAL TIRE AND WHEEL ASSEMBLY, STANDARD RIB TIRE AND WHEEL ASSEMBLY, POWER RIB TIRE AND WHEEL ASSEMBLY, SOFT TRAC TIRE AND WHEEL ASSEMBLY, TERRAGARD UNMOUNTED TIRE, STANDARD RIB UNMOUNTED TIRE, POWER RIB UNMOUNTED TIRE, SOFT TRAC UNMOUNTED TIRE, TERRAGARD UNMOUNTED TIRE, INDUSTRIAL KEY SWITCH, KEY - 12 VOLT
INLCUDES ITEM 11 SWITCH, KEY - 36 VOLT
INLCUDES ITEM 11 DECAL, ON/OFF SNAP WASHER KIT (BLACK) VEHICLE LOADING DECAL VEHICLE LOADING DECAL TILT BED DECAL BOOT BACKUP STRIP DECAL - LEFT HAND SIDE DECAL - RIGHT HAND SIDE DECAL - LEFT HAND SIDE DECAL - RIGHT HAND SIDE PINCH DECAL LATCH DECAL MOVING PARTS DECAL (ON FRAME) DANGER DECAL (NOT SHOWN) HOT MANIFOLD DECAL WHEEL RIM, WHITE
UNITS PER
VEHICLE
CA-II GAS
1 1 1 1
1 1 1 16 2 4 4 4 4
N R N R N R N R N R PR 1
1 2
1 1 1
1 1 1 1 1 1 1
N R
UNITS PER
VEHICLE
CA-I GAS
1 1 1 1
1 1 1 16 2 4 4 4 4
N R N R N R N R AIR PR 1
1 2 1
1 1 1 1
1 1 1
1 N R
UNITS PER
VEHICLE
CA-I ELEC.
1 1 1 1 1
1 1 16 2 4 4 4 4
N R N R N R N R N R PR
1
1 2 1 1 1 1 1 1
1 1
N R
3 TYPICAL
\ TYPICAL 5 2 PLACES
DETAIL A 1 DETAIL B I DETAIL C 1 DETAIL D
FRONT COWL - CARRYALL-I
13
11 14 TYPICAL 2 PLACES
TYPICAL 6 PLACES, ITEM I2 TYPICAL 4 PLACES. ITEM 13 PLACES TYPICAL 2 PLACES
FRONT COWL - CARRYALL-I
TYPICAL 5 2 PLACES
/
DETAIL A
FRONT COWL - CARRYALL-II
DETAIL B DETAIL C DETAIL D
10
DETAIL E
14 TYPICAL 2 PLACES PLACES
TYPICAL 6 PLACES, ITEM 12 TYPICAL 4 PLACES, ITEM 13 TYPICAL 2 PLACES TYPICAL 2 PLACES
FRONT COWL - CARRYALL-II
DETAIL A
TYPICAL 3 PLACES AT EACH FENDER
DETAIL B
TYPICAL 2 PLACES
DETAIL C
TYPICAL 2 PLACES
DETAIL D
TYPICAL 4 PLACES
REAR COVER - CARRYALL-I AND CARRYALL-I1
LOCATED AT 24 REAR OF ITEM 3
DETAIL A 1 DETAIL B 1 DETAIL C I DETAIL 0 1 DETAIL E I
SEAT BOTTOM AND SEAT BACKS - CARRYALL-I AND CARRYALL-II
TYPICAL 8 PLACES I TYPICAL 16 PLACES I TYPICAL 4 PLACES / TYPICAL 2 PLACES TYPICAL 4 PLACES, ITEM 8,s TYPICAL 2 PLACES, ITEM 18
A
DETAIL A I DETAIL B 1 DETAIL C I DETAIL D
TILT BED AND LATCH - CARRYALL-I
8 TYPICAL 4 PLACES
12
TYPICAL 2 PLACES TYPICAL 4 PLACES T Y P I C A L 2 P L A C E S
TILT BED AND LATCH - CARRYALL-I
DETAIL A I DETAIL B I DETAIL C 1 DETAIL D
TILT BED PROP ROD AND HINGE - CARRYALL-II
I T Y P I C A L 4 P L A C E S I T Y P I C A L 4 P L A C E S T Y P I C A L 2 PLACES
3
DETAIL A
TILT BED AND LATCH - CARRYALL-II
1 TYPICAL 4 PLACES I TYPICAL PLACES
8 10
DETAIL B
TYPICAL 4 PLACES
DETAIL C
T Y P I C A L 2 P L A C E S
DETAIL D
TILT BED AND LATCH - CARRYALL-II
Section 2
DRIVE UNIT
DRIVE UNIT
DRIVE UNlT
DRIVE UNlT INCLUDES ALL ITEMS EXCEPT 8, 9, 10, 11 AND 43
AXLE ASSEMBLY, RIGHT INCLUDES ITEMS 2, 16, 18 AND 19
LUG STUD BOLT (10 X 30) LOCKWASHER INPUT SHAFT OIL SEAL GEAR CASE - RIGHT HAND BREATHER PLUG SHIFT CABLE SUPPORT BRACKET KIT (GAS VEHICLE ONLY)
INCLUDES ITEMS 9, 10, 11 AND 43 1/4" FLATWASHER 1/4-20 X 4" HEX BOLT 1/4-20 X 3-1/2" HEX BOLT GASKET INNER AXLE, TUBE BEARING GASKET - AXLE TUBE AXLE TUBE ASSEMBLY - RIGHT HAND BUSHING WlTH GROOVE IN END AXLE SHAFT OIL SEAL OUTER AXLE TUBE BEARING CIRCLIP, TYPE-C INPUT GEAR BEARING SHAFT, INPUT INTERMEDIATE GEAR BEARING INTERMEDIATE GEAR - SMALL KEY, SUNK INTERMEDIATE GEAR - LARGE GEAR CASE - LEFT HAND FILL PLUG WlTH GASKET BOLT (6 X 50) PIN, DOWEL BOLT (8 X 37) PLATE, LOCK OUTPUT GEAR DIFFERENTIAL PIN DIFFERENTIAL GEAR CASE - LEFT HAND PLATE, THRUST (DIFFERENTIAL GEAR) DIFFERENTIAL GEAR PLATE, THRUST (IDLER GEAR) DIFFERENTIAL IDLER GEAR DIFFERENTIAL GEAR CASE - RIGHT HAND SHIM AXLE TUBE ASSEMBLY - LEFT HAND AXLE ASSEMBLY, LEFT
INCLUDES ITEMS 2, 16, 18 AND 19 1/4-20 NYLON LOCKNUT
UNITS PER
VEHICLE
ITEM NUMBER
PART NUMBER DESCRIPTION
1 2 3 4
Section 3
BRAKES, PEDAL AND CABLE ASSEMBLY
BRAKE CLUSTER, RIGHT HAND AND LEFT HAND
BRAKE PEDAL AND CABLE ASSEMBLY
ACCELERATOR PEDAL ASSEMBLY
Section 4
STEERING AND FRONT SUSPENSION
STEERING COLUMN ASSEMBLY - STEEL
STEERING COLUMN ASSEMBLY - STEEL
STEERING COLUMN - ALUMINUM
STEERING COLUMN - ALUMINUM
STEERING ASSEMBLY
FRONT SUSPENSION ASSEMBLY - A-PLATE
UNITS PER
VEHICLE
1
4 3 1 1 1
2 2 6 6 1 1
4 2 2 2 4 2 1
2 2 2 2 2 2 1 1 1
8 2 1 9 8 4 1
4 2 2 2 2 2
4 8 8 2 1
ITEM NUMBER
1
2 3 4 5 6
7
8 9
10 11 12
13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
29 30 31 32 33 34 35
36 37 38 39 40 41
42 4 3 44 45 46
PART NUMBER
7539
1015597 1308
1010219 7555 7540
1010126 1014235
1624 1010138 1012496 1015589
7719 1010125
209 1010117
8754 1010150 1010348
8067 7048
1010121 7602 1035 8755
1010124 8745
1013867
1015583 1012303 1014276
706 357
1010200 1010347
334 1010005
7840 1011887
7910 1011894
1011393 1011304 1011390 1013135 1015586
FRONT SUSPENSION ASSEMBLY - A-PLATE
DESCRIPTION 1 2 3 4
JOINT, RIGHT HAND BALL INCLUDES ITEM 23
1/4-28 THREAD FORMING GREASE FITTING NUT, 1/2-20 HEX ROD, TIE NUT, 1/2-20 LEFT HAND HEX JOINT, LEFT HAND BALL
INCLUDES ITEM 23 BOLT, 33/8-16 SHOULDER HEX ABSORBER, SHOCK BOLT, 3/8-16 HEX LOCKNUT, 3/8-16 SHOCK SUPPORT WELD ASSEMBLY "A" PLATE SUBASSEMBLY (LEFT HAND)
INCLUDES ITEMS 2 AND 13 AND 29 BUSHING, BRONZE BOLT, 3/8-16 SHOULDER HEX LOCKWASHER, 1/2" CLEVIS, UPPER LOCKNUT, 3/8-16 NYLON WASHER, THRUST SPINDLE LEFT HAND ASSEMBLY
INCLUDES ITEMS 2, 20, AND 21 BUSHING, SPINDLE BUSHING, 3/4" BRONZE KING PIN ASSEMBLY NUT, 3/8-24 SLOTTED HEX PIN, COTTER 3/32 X 1" BOLT, 3/8-16 HEX PLATE, FRONT SPRING MOUNTING ADJUSTER, FRONT SPRING ECCENTRIC SPRING, FRONT - CARRYALL-! AND CARRYALL-II
INCLUDES ITEMS 27 AND 32 BUSHING, URETHANE BUSHING, 3/8" STEEL PLATE, FRONT SPRING RETAINER NUT, 3/8-16 HEX LOCKWASHER, 3/8" BOLT, 33/8-16 SPINDLE RIGHT HAND ASSEMBLY
INCLUDES ITEMS 2, 20 AND 21 FLATWASHER, 3 / 8 FLATWASHER, SPECIAL NUT, 3/4-16 SLOTTED HEX COVER, DUST PIN, COTTER 5/32 X 1" HUB ASSEMBLY
INCLUDES ITEMS 42 AND 43 BEARING, HUB PACKAGE (2 PIECES) STUD, LUG NUT, LUG SEAL, DUST " A PLATE ASSEMBLY, RIGHT HAND
INCLUDES ITEMS 2, 13 AND 29
--
FRONT SUSPENSION ASSEMBLY - DELTA A-PLATE
Section 5
ELECTRICAL AND BATTERY
VOLTAGE REGULATOR
REVERSE
I 1 l 2 V BATTERY
WIRING - GAS VEHICLE
ELECTRICAL COMPONENT BOX
ELECTRICAL COMPONENT BOX
NUMBER
2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
PART NUMBER
STARTER-GENERATOR MOUNTING
??.=!A DESCRIPTION
STARTER-GENERATOR MOUNTING BRACKET BELT PULLEY ADJUSTING BRACKET HEX HEAD SCRNV, 3/8-16 X 1-1/4 LOCKWASHER, 318'' DIAMETER HEX NUT, 3/8-16 HEX HEAD SCREW, M81.25 X 25MM LOCKWASHER, 5/16" DIAMETER TORX HEAD SCREW, M81.25 X 18MM ROUND HEAD SQUARE NECK BOLT, 5/16-18 X 1 HEX NUT, 5/16-18 #6 BLACK WIRE ASSEMBLY GROUND WlRE NYLON LOCK NUT, 5/16-18 FLATWASHER, 5/16" DIAMETER HEX HEAD CAP SCREW, 5/16-18 X 3/4
STARTER-GENERATOR ASSEMBLY ITEM
NUMBER
1 2 3 4 5 6 7 8 9
10 11
12 13 14 15
16 17
18 19 20 21 22 23
24 25
26 27 28
PART NUMBER
NO # NO #
1013000 NO #
1012999 1013001 1013002 1013003 1013004
1013005 1013006
NO # 1013009 1013010 1013007
NO # 1013017
NO # 1013013 1013011
NO # 1013014 1014699
1013016 1012990
1012992 1012993 1012991
1 2 3 DESCRIPTION
HEX NUT, MI4 X 1.5 LOCKWASHER, MI4 SPACER CROSS-RECESSED SCREW, M5 X 18 WITH LOCKWASHERS AND FLATWASHERS OUTPUT SHAFT END BELL DOUBLE SEALED BALL BEARING BEARING RETAINER KEY ARMATURE ASSEMBLY
INCLUDES ITEMS 3, 6, 7, 10 AND ARMATURE DOUBLE SEALED BALL BEARING FRAME ASSEMBLY
INCLUDES ITEMS 12 THRU 18 AND FRAME POLE PIECE POLE PIECE SCREW FIELD COIL ASSEMBLY TERMINAL HARDWARE KIT
INCLUDES NUTS, LOCKWASHERS AND FLATWASHERS INSULATOR TERMINAL HARDWARE KIT
INCLUDES NUTS, LOCKWASHERS AND FLATWASHERS INSULATOR
CROSSOVER LEAD BRUSH HOLDER SCREW, M5 X 16 WITH LOCKWASHER SCREW, M4 X 10 WITH LOCKWASHER BRUSH PACKAGE
INCLUDES 4 BRUSHES BRUSH SPRING TERMINAL HARDWARE KIT
INCLUDES NUTS, LOCKWASHERS, FLATWASHERS AND INSULATORS CLAMP BOLT, 6 X 180 COMMUTATOR END BELL BRUSH INSPECTION PORT COVER
UNITS PER
VEHICLE
1 1 1 3 1 1 1 1 1
1 1
4 4 1 2
2 1
2 1 2 4 1
4 2
2 1 4
F&R SHIFTER ASSEMBLY
F&R SHIFTER ASSEMBLY
q g TYP
BUZZER SHOWN REPLACED BY ITEM #9 (1016851)
ITEM NUMBER
9 10 11
CENTER DASH PANEL
8
PART NUMBER
REVERSE BUZZER - DASH MOUNTED
1 2 3 4 DESCRIPTION
REVERSE BUZZER #4-24 X ,330 SCREW PAN HEAD HI-LO WIRE ASSEMBLY, BLACK (GAS VEHICLE ONLY - NOT SHOWN)
UNITS PER
VEHICLE
1 2 1
5-11
BATTERY
Section 6
ENGINE
Effective Carryall-l Serial Number FG9201-270568 Effective Carryall-ll Serial Number EG9201-270555
For engine prior to above, see CLUB CAR Illustrated Parts List #I014650 or #1013932.
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
UNITS PER
VEHICLE
1 1 2 2 2 2 2 2 2 2 2 2 1 1 I 1 1 1 1 1 1
2 2 1 2 1 I 6 1
ITEM NUMBER
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29
PART NUMBER
1016442 1016436 1016583 1016569 1016542 1016545 1016451 1016450 1016449 1016523 1016479 1016560 1016518 1016566 1016519 1016448 1016447 101 6544 1016474 101 6483 1016431
1016563 1016489 1016452 1016471 1016549 1016517 10 16458 1016430
ENGINE
DESCRIPTION 1 2 3 4
ROCKER CASE ROCKER CASE GASKET FLANGED BOLT, M6 X 1.0 X 35MM LONG O-RING SCREW HEX NUT ROCKER ARM COLLET VALVE SPRING RETAINER ENGINE VALVE SPRING SPRING SEAT SNAP RING VALVE GUIDE (EXHAUST) OIL SEAL VALVE GUIDE (INTAKE) EXHAUST VALVE INTAKE VALVE SCREW PLATE VALVE CYLINDER HEAD
INCLUDES ITEMS 12, 13 AND 15 PIN STUD BOLT ROCKER SHAFT PUSH ROD WASHER TYPE-E ClRCLlP FLANGED BOLT, M8 X 1.25 X 45MM LONG HEAD GASKET
TYPICAL 2 PLACES
ENGINE
ENGINE
ENGINE
Section 7
FUEL, INTAKE AND GOVERNOR SYSTEM
FUEL SYSTEM ASSEMBLY
DETAIL C
34
30
DETAIL A
TANK CONNECTION
FRAME CONNECTION
DETAIL B
CARBURETOR ASSEMBLY
GOVERNOR GUARD AND INTAKE HOSE
EXPANSION CHAMBER, CHOKE AND FILTER
GOVERNOR AND ACCELERATOR CABLES
GOVERNOR AND ACCELERATOR CABLES
Section 8
EXHAUST SYSTEM
EXHAUST SYSTEM
Section 9
TORQUE CONVERTER
DRIVE CLUTCH ASSEMBLY
DRIVEN CLUTCH ASSEMBLY
DRIVEN CLUTCH ASSEMBLY ITEM
NUMBER
1 2 3 4 5 6
7 8 9
10 11 12 13 14
PART NUMBER
101636041 1012455 1016203
7173 7174
1012571 1016360-01
1014080 1014078 1014077 1016359 1012836 1014076 1014072 1014070 1014454
1 2 4 DESCRIPTION
DRIVEN CLUTCH ASSEMBLY (CARRYALL-I AND CARRYALL-II) SHAFT KEY DRIVE BELT HEX HEAD BOLT, 5/16-18 X 3/4 LOCKWASHER, 5/16" DIAMETER HEAVY FLATWASHER, 5/16 DIAMETER DRIVEN CLUTCH ASSEMBLY
INCLUDES ITEMS 7 THRU 14 RETAINING RING SHORT KEY CAM 75" SPRING SOC HEAD CAP SCREW, #8-32 X 3/4 DRIVE BUTTON MOVABLE FACE ASSEMBLY FIXED FACE ASSEMBLY DRIVEN CLUTCH BUTTON KIT
INCLUDES ITEMS 11 AND 12
UNITS PER
VEHICLE
1 1 1 1 1 1
1 1 1 1 3 3 1 1 1
TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY UNITS
PER VEHICLE
1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 3 2 2 1 2 2 1 2 1 3 1 1
N R N R 1 4 1 1 1 1 1 1 1
N R N R AJR
1 2 1 1 1 1 1 1 1 1 1 2
ITEM NUMBER
1 2 3 4 5 6 7 8 9
10 11 13 14 15 16 17 18 19 19A 20 21 22 23 24 25 29 30 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 55 56 57 58 59 60 61 61 61 62 63 64 65 66 67 68 69 70 71 72 73 -
PART NUMBER
1015747 1012761 1012759 1012755 1016598 1012760 1012764 1012763 1012757 1012758 1016540 1012772 1015710 1016513 1012770 1012766 1012765 1012762 1010954 1012602 1012414 1012753 1012751 1012754 1012767
8717 1012711 1012714 1013759 1013960 1012719 1012710 1012717
7336 1016337 1012735 1016591 1012742 1012743 1012734 1012741 1012738 1012740 1012739 1012737 1012783 1012784 1012733 1012718 1012715 1012732 1012730 1012731 1012729 1012728 1012716 1012723 1012724 1012725 1012722 1012727 1016594 1012720 1012752 1012750 1012748 1012747 1012746 1012745 1012749 1016338
1 2 3 4 DESCRIPTION
TRANSMISSION ASSEMBLY BALL BEARING SPACER-THICK GOVERNOR GEAR, 41 TOOTH GOVERNOR SHAFT GOVERNOR SHAFT KEY SCREW, M4 X 0.7 X 6MM GOVERNOR ARM, INTERNAL GOVERNOR SLEEVE SPACER-THIN BOLT, M6 X 1 X 25MM HEX GOVERNOR ARM PIVOT GOVERNOR ARM, EXTERNAL WASHER, FLAT NUT, M6 X 1 SNAP RING WASHER GOVERNOR ARM SHAFT BALL STUD CAP SCREW, SOCKET HEAD, 10-24 X 3/8" TRANSMISSION SHIFTER ARM, OUTSIDE SHIFTER SHAFT KEY SHIFTER SHAFT O-RING OIL SEAL LOCKNUT, 1/4-28 NYLON BREATHER OIL SEAL DRAIN PLUG WITH GASKET GEAR CASE BOLT, M6 X 1 X 14MM HEX DOWEL PIN CASE GASKET BALL BEARING THRUST WASHER PLUG GEAR ASSEMBLY, 36 TOOTH SYNCHRONIZER RING THRUST WASHER OUTPUT SHAFT SYNCHRO SPRING CLUTCH HUB SYNCHRO INSERT SLEEVE GEAR ASSEMBLY, 34 TOOTH SHIM 0.2MM SHIM O.1MM FLANGE NUT, MI2 X 1.25 BOLT, M6 X 1 X 20MM HEX COVER O-RING THRUST WASHER NEEDLE BEARING REVERSE IDLER GEAR IDLER SHAFT NEEDLE BEARING THRUST WASHER, 3.OMM THRUST WASHER, 3.3MM WHITE THRUST WASHER, 3.6MM YELLOW GEAR, 25 TOOTH SNAP RING GEAR, 27 TOOTH INPUT SHAFT ROLL PIN SHIFTER ARM LEVER, INSIDE SHIFTER SPRING SHIFTER BALL SLEEVE SHIFT ARM SHIFT ROD ROLL PIN BELLEVILLE SPRING
Section 11
REAR SUSPENSION
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY ITEM
NUMBER
1 2 3 4 5 6 7
8 9
10 11 12 13 14 15 16 17 18 19 20
PART NUMBER
1012304 1010138 1012303 1015583 1010145 1011415 1012781
1014902 1014675 1014557 1014555
8755 1010188 1010193 1014552 1014546
1241 7473
1014573 1014901
1 2 3 4 DESCRIPTION
REAR SPRING SHACKLE DIMPLED LOCKNUT, 3/8-16 UNC STEEL BUSHING URETHANE BUSHING NUT, 3/8-24 UNC HEX SHOCK ABSORBER CUSHION KIT SHOCK ABSORBER KIT
INCLUDES ITEM 6 "U" BOLT REAR SPRING FLATWASHER, 7/16" NYLON LOCKNUT, 7/16-14 BOLT, HEX, 3/8-16 UNC X 3-3/8" DIMPLED LOCKNUT, 5/8-11 FLATWASHER, 518 OVERLOAD BUMPER OVERLOAD BUMPER MOUNT FLATWASHER, 5/16 NYLON LOCKNUT, 5/16-18 SPRING RETAINER SPACER - OVERLOAD BUMPER
UNITS PER
VEHICLE
4 6 4 12 2 2 1
2 2 4 4 6 2 2 2 2 2 2 2 2
Section 12
ELECTRICAL
POWER WIRING - ELECTRIC VEHICLE
19-
14
33
44 DETAIL A
FRAME
DETAIL B
UNITS PER
VEHICLE
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 6 1 1 1 1 1 1 2 6 2 6 3 3 3 6 18 6 4 1
1 2 2 2 2
ITEM NUMBER
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 4 4 45
46 47 48 49 50
7
PART NUMBER
1016070 1016069 1012651 1016068 1014036 1014035 1014034 1014033 1014032 1014828 1014030 1014029 1014022 1013092 1014024 1012230 1014023 1012237 1011010 1011007 1014039 1011006 1011069 1014040 1010958
8797 1012143 1012085 1012142 1013628 1013649
4107 1013266 1016616-01
8795 8796
1012022 1606
1010908 1013683 1014305 1011578
1016 1014516
8016 1012285
7893 1242 7174
POWER WIRING - ELECTRIC VEHICLE
1 2 3 4 DESCRIPTION
WIRE ASSEMBLY #6 BROWN WIRE ASSEMBLY #6 PURPLE WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 GREY WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 YELLOW WIRE ASSEMBLY #6 ORANGE WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #18 RED WIRE ASSEMBLY #10 RED WIRE ASSEMBLY #18 ORANGE WIRE ASSEMBLY #18 WHITE WIRE ASSEMBLY #18 GREEN WIRE ASSEMBLY #10 RED WIRE ASSEMBLY #10 WHITE WIRE ASSEMBLY #18 RED WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #18 BLUE WIRE ASSEMBLY #6 RED WIRE ASSEMBLY #18 YELLOW WIRE ASSEMBLY #6 BLACK NUT #lo-32, BRASS FUSE LENS FUSE, 80 AMP FUSE HOLDER FUSE AND RECEPTACLE MOUNTING BRACKET RECEPTACLE BEZEL CHARGER RECEPTACLE SCREW, PHILLIPS HEAD, TYPE BT, #8-18 X 1/2" CLUB CAR 6 VOLT BATTERY SELF TAPPING SCREW, PHILLIPS PAN HEAD # 7 X 1-314" SELF TAPPING SCREW, PHILLIPS PAN HEAD # 7 X 3/4" CABLE CLAMP POP RIVET, 3/16" BATTERY HOLD DOWN "J" BOLT HEX NUT, 5/16-18 UNC S.S. FLATWASHER, TYPE B, 5/16" #10 SPLIT LOCKWASHER FUSE LINK KIT (NOT SHOWN)
INCLUDES ITEMS 27, 28, 29, 30 AND 44 SOLENOID - 36 VOLT 1/4-20 X 5/8" THREAD ROLLING SCREW #lo-32 HEX NUT 5/16 X 18 HEX NUT WASHER, 5/16 HELICAL SPRING
V-GLIDE WIPER SWITCH
RESISTOR AND BOARD ASSEMBLY - V-GLIDE
FORWARD AND REVERSE SWITCH ASSEMBLY - V-GLIDE
PART NUMBER
FORWARD AND REVERSE SWITCH ASSEMBLY - V-GLIDE
1 2 3 4 DESCRIPTION
FORWARD AND REVERSE SWITCH ASSEMBLY COMPLETE EXCLUDING ITEMS 1 AND 2 AND MOUNTING HARDWARE, ITEMS 14, 15, 16 AND 18
SCREW, PHILLIPS MACHINE, #8-32 SWITCH HANDLE, FORWARD AND REVERSE ROLL PIN, 1/8 X 1" SHAFT, FORWARD AND REVERSE SWITCH NUT, HEX, #4-40 UNC LOCKWASHER, #4 LIMIT SWITCH, FORWARD AND REVERSE SCREW, SLOTTED ROUND HEAD, #4-40 X 1-1/8" ROTOR CONTACT SWITCH ROTOR, FORWARD AND REVERSE ROLL PIN, 3/16" X 1-3/8" FLATWASHER, 3 / 8 SHAFT SPRING, FORWARD AND REVERSE SCREW, HEX HEAD MACHINE, #lo-24 LOCKWASHER, INTERNAL TOOTH #10 LOCKNUT, NYLON, 1/4-20 SWITCH CASE, FORWARD AND REVERSE SCREW, TRUSS HEAD PHILLIPS, 1/4-20 X 2" WASHER, PLASTIC, 3/8" BEARING
- UNITS
PER VEHICLE -
1 1 1 1 2 2 1 2 2 1 1 2 1 2 2 3 1 3 1 2
1
DETAIL A
POWER WIRING - SOLID STATE CONTROLLER
POWER WIRING - SOLID STATE CONTROLLER UNITS
PER VEHICLE
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 4 4 4 2 2 2 2 2 3 3 1 1 1 1 1 1 1 6 3 6 18 6
ITEM NUMBER
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 21 22 23 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
.
PART NUMBER
1015879 1015860 1015861 1016137 1015856 1015857 1015863 1015864 1015866 1016135 1016121 1015858 1015865 1015859 1016134 1016133 1016122
8016 1014948 1014947
7847 451
1028 1016631
7174 1242 403 451
1028 8450 8049 1606
1012022 1014854 1014855 1016142 1016019 1014839 1016018 1014749 101661641 1010908 1013683 1014305 1011578
DESCRIPTION 1 2 3 4
CONTROLLER WIRING ASSEMBLY WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #18 BLACK WIRE ASSEMBLY #18 WHITE WIRE ASSEMBLY #18 YELLOW WIRE ASSEMBLY #I8 RED WIRE ASSEMBLY #18 GREEN WIRE ASSEMBLY #6 YELLOW WIRE ASSEMBLY #I8 RED WIRE ASSEMBLY #18 RED WIRE ASSEMBLY #18 ORANGE WIRE ASSEMBLY #I8 BLUE WIRE ASSEMBLY #I8 BLACWHITE SOLENOID - 36 VOLT DIODE ASSEMBLY RESISTOR ASSEMBLY 1/4-20 X 314 HEX HEAD SCREW 114 HELICAL SPRING LOCKWASHER 1/4-20 HEX NUT PUSH NUT ,187 5/16 HELICAL SPRING LOCKWASHER (ATTACHES WIRES TO MOTOR) 5/16-18 HEX NUT (ATTACHES WIRES TO MOTOR) 1/4-20 X 5 / 8 HEX HEAD BOLT (ATTACh5S WIRES TO FORWARD & REVERSE CONTACT BARS) 1/4 LOCKWASHER (ATTACHES WIRES TO FORWARD & REVERSE CONTACT BARS) 1/4-20 HEX NUT (ATTACHES WIRES TO FORWARD & REVERSE CONTACT BARS) #lo-24 X 1 / 2 HEX HEAD SCREW (ATTACHES WIRES TO FORWARD & REVERSE ROTOR) #I0 LOCKWASHER (ATTACHES WIRES TO FORWARD & REVERSE ROTOR) 3/16 POP RIVET CABLE CLAMP WIRE ASSEMBLY #6 ORANGE WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #18 BLUE WIRE ASSEMBLY #18 WHITE WIRE ASSEMBLY #I8 GREENWHITE WIRE ASSEMBLY #I8 BLACK ELECTRONIC CONTROLLER CLUB CAR 6 VOLT BATTERY BATTERY HOLD DOWN (NOT SHOWN) "J" BOLT (NOT SHOWN) HEX NUT, 5/16-18 UNC STAINLESS STEEL (NOT SHOWN) FLATWASHER, TYPE B, 5/16 (NOT SHOWN)
F&R SWITCH - SOLID STATE CONTROLLER
i , 9,m.-.. \ , , -- BACK VIEW
" f
V-GLIDE WIPER SWITCH - SOLID STATE CONTROLLER
UNITS PER
VEHICLE
1 5 7 3 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 2 1 1 2 2 2 2 1 2 2 1 1 1 2 1 1 1 2 1 1 1 1 1 2
4
2
2
4
V-GLIDE WlPER SWITCH - SOLID STATE CONTROLLER
1 2 3 4 DESCRIPTION
V-GLIDE WlPER SWITCH - SOLID STATE CONTROLLER SPEED CONTROLLER CASE 1/4-20 UNC HEX NUT, BRASS 1 / 4 SPLIT LOCKWASHER 1/4"-20 BRASS JAM NUT 5/16"-18 UNC NYLON LOCKNUT 1/4" X 1/4-28, SHORT BALL STUD SPEED CONTROLLER BELL CRANK 1/4-28 DIMPLED LOCKNUT 3/8" X 1/2" FLANGE BEARING 1/4"-20 X 2.00 HEX CAP SCREW, BRONZE SPEED CONTROLLER COVER #I032 UNF HEX NUT SPEED CONTROLLER SHAFT AND CARRIER SPEED CONTROLLER BRUSH SPRING SPEED CONTROLLER ADJUSTING STUD M-40 UNC TYPE " F SCREW #4 SPLIT LOCKWASHER SPEED CONTROLLER ARM SPEED CONTROLLER BRUSH M-40 UNC X 3 / 4 ROUND HEAD SCREW LIMIT SWITCH SPLIT GROMMET M-40 UNC HEX NUT #lo-24 X 3 / 4 ROUND HEAD BOLT #10 SPLIT LOCKWASHER #10 HEX NUT ACCELERATOR ROD 1/4-28 JAM NUT BALL JOINT BUMPER, SPEED CONTROLLER SHIM, SPEED CONTROLLER HAIR SPRING COTTER PIN SPEED CONTROLLER DECAL WIPER SWITCH RESISTOR PROTECTOR WIRE ASSEMBLY #18 BLACK RESISTOR ASSEMBLY 910R RESISTOR ASSEMBLY 620R RESISTOR ASSEMBLY 750R RESISTOR ASSEMBLY 820R RESISTOR ASSEMBLY 1100R #18 GREENNHITE WIRE ASSEMBLY #18 BLUE WIRE ASSEMBLY #8-32 X .44 PAN HEAD SCREW (NOT SHOWN)
(ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8 PLAIN WASHER (NOT SHOWN)
(ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8-32 HEX NUT (NOT SHOWN)
(ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8-32 HEX MALWFEMALE STANDOFF (NOT SHOWN)
(ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8 EXTERNAL TOOTH LOCKWASHER (NOT SHOWN)
(ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE)
ITEM NUMBER
1 2 3 4 5 6 7 8 9
10 11 12 13 14 I5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44
45
46
47
4 8
PART NUMBER
1014917 1014 451
1014253 7473
1012353 1014003
8449 1012903 1014189 1013886
7893 1014017 1013998 1014000 1014019
8058 1013887 1013860
8056 1014807 1014010
8057 1014109 1016175
1017 1014016 1011084 1011734 1014414 1014367 1014413 1016109 1016061 1016018 1016017 1016016 1016015 1016014 1016013 1014839 1016142 1016092
1013529
1011571
1016090
1012076
ITEM NUMBER
PART NUMBER
REVERSE BUZZER - FRAME MOUNTED
1 2 3 4 DESCRIPTION
BUZZER KIT INCLUDES ITEMS 2 THRU 8
SCREW, ROUND HEAD #4-40 X 3/4 NYLON SHOULDER WASHER #4 FLATWASHER #4 LOCKWASHER #4 HEX NUT
ITEM NUMBER
7 8
PART NUMBER
1016851 10 16849
REVERSE BUZZER - DASH MOUNTED
1 2 3 4 DESCRIPTION
REVERSE BUZZER #4-24 X 330 SCREW, PAN HEAD HI-LO
UNITS PER
VEHICLE
1 2
Section 13
BATTERY CHARGER
USE THIS INFORMATION
MODEL: I't5'~)
INPUT: 120'ds-
u
MODEL 13800 ACCU-POWER CHARGER
MODEL 14000 ULTRA-POWER CHARGER
ITEM NUMBER
1
2 3 4 4 4 4 5 5 6 7 8 9
10 11 12
PART NUMBER
1015909
1012098 1015917 1016433-01 1016433-02 1016433-03 101643344 101591661 1015916-02 1015912 1015914 1015911 1015910 1015908 1015913 1012101 1016463-01
MODEL 14000 ULTRA-POWER CHARGER
1 2 , DESCRIPTION
CASE ASSEMBLY INCLUDES FASTENERS
STRAIN RELIEF, DC CORD STRAIN RELIEF, AC CORD DC CORDSET, 12 AWG X 110 INCHES LONG DC CORDSFT, 12 AWG X 146 INCHES LONG DC CORDSET, 10 AWG X 242 INCHES LONG DC CORDSFT, 10 AWG X 110 INCHES LONG AC CORDSET, 16 AWG X 80 INCHES LONG AC CORDSFT, 16 AWG X 110 INCHES LONG TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY WITH DIODES 36 VDC RELAY CAPACITOR TIMER KIT ASSEMBLY CONTROL CABLE ASSEMBLY FUSE ASSEMBLY ULTRA-POWER CHARGER ASSEMBLY
INCLUDES ITEMS 1 THRU 3, 6 THRU 12, 1 EACH OF ITEMS 4 AND 5
UNITS PER
VEHICLE
1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Section 14
MOTOR
MOTOR ASSEMBLY FOR CLUB CAR MODELS 1012191 AND 1014678
MOTOR ASSEMBLY FOR CLUB CAR MODELS 1012191 AND 1014678
Section 15
REAR SUSPENSION
REAR SUSPENSION ASSEMBLY - CARRYALL-I ELECTRIC
pr NUMBER
PART NUMBER
REAR SUSPENSION ASSEMBLY - CARRYALL-I ELECTRIC
1 2 3 4 DESCRIPTION
DIMPLED LOCKNUT, 3/8-16 UNC URETHANE BUSHING REAR SPRING BOLT, HEX, 3/8-16 UNC X 3-3/8 LOCKNUT, NYLON 5/16-18 FLATWASHER, 5/16 BUMPER BUMPER MOUNT - ANGLED " U BOLT REAR SPRING SHACKLE SPRING RETAINER SHOCK MOUNT, RIGHT-HAND (NOT SHOWN) SHOCK MOUNT, LEFT-HAND FLATWASHER, 7/16 LOCKNUT, NYLON 7/16-14 SHOCK ABSORBER CUSHION KIT SHOCK NUT, HEX 3/8-24 BRAKE CABLE HANGER SHOCK ABSORBER KIT
INCLUDES ITEMS 15 (4) AND 16 (2) STEEL BUSHING
Club Car, Inc.
P.O. Box 204658
Augusta, GA 30917-4658
USA
Web www.clubcar.com
Phone 1.706.863.3000
1.800.ClubCar
Int’l +1 706.863.3000
Fax 1.706.863.5808